Dismantleable chair

ABSTRACT

A dismantleable chair composed of at least two panel members. The panel members are formed from generally flat sheets of some material such as plywood by a molding process. Each panel member has a looped or arcuate section of such an extent and radius that the adjacent portions of the panel member extend approximately normal to one another. The looped portions have cross-sections that are approximately the same so that they can be nested together in a disassembled configuration. When assembled, the panels define therebetween a generally four sided closed figure. The panel members are secured together in the assembled configuration by a minimum number of releasable mounting members at the lower front and upper rear corners of this four sided figure. A back portion to the chair is provided either as a separate panel or as an extension of the front panel. The arms of the normally rear panel member can be of different lengths so as to provide adjustability between a normally upright and a reclined configuration.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent application No. 60/524,192, filed on Nov. 21, 2003.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates in general to the field of dismantleable furniture and, in particular, to dismantleable chairs made from generally monolithic, reversible, arcuate panels, which panels, when disassembled, are generally nestable.

2.Description of the Prior Art

Many take-apart or breakdown chairs have been proposed previously. Chairs composed of monolithic arcuate panels have also been proposed. Breakdown chairs are typically useful where temporary seating is required, yet when they are not in use they can be conveniently disassembled and stored in a space efficient manner. Since such chairs are often used temporarily, it is often required that they cost less than conventional non-break-down or folding chairs, otherwise any additional cost could outweigh the advantages gained from their disassembleable nature. In addition, dismantleable chairs must be of sufficient strength and rigidity so as to not only be safe, but also to be comfortable and sturdy enough impart confidence in the minds of their users.

Previous attempts to create inexpensive dismantleable chairs include those disclosed, for example, in U.S. Pat. No. 5,765,922 to Hsia, in U.S. Pat. No. 5,992,938 to Jones, U.S. Pat. No. 4,225,180 to Gillis, U.S. Pat. No. 4,188,067 to Elmer, and in U.S. Pat. No. 4,712,837 to Swilley. These proposed expedients generally suffer from numerous shortcomings. Further, the configurations of typical previous dismantleable chairs lacked adjustability.

Previous attempts to form arcuate chair members from initially flat molded sheets have been less than totally satisfactory at least in the areas of dismantleability, rigidity, sturdiness, and the like. See, for example, 100 Masterpieces from the Vitra Design Museum Collection, 1996, ISBN 3-9804070-3-9, and Charlotte & Peter Fiell, 1000 Chairs, 1997, ISBN 3-8228-7965-7.

Thus, there is a need to provide at a reasonable cost a comfortable, rigid, aesthetically pleasing, dismantleable chair that is configurable as to form and composed of a minimum number of arcuate panels, particularly interchangeable and/or reversible arcuate panels, that are nestable when disassembled. Achieving an optimized balance of these considerations has proven problematic.

These and other difficulties of the prior art have been overcome according to the present invention.

BRIEF SUMMARY OF THE INVENTION

A preferred embodiment of the dismantleable chair according to the present invention comprises, for example, a front panel and a rear panel. These components are conveniently fabricated, for example, from sheets of deformable—particularly moldable—materials including, for instance, sheets of plywood, plastic, laminated fiberboard, and the like. As shaped, each of the front and rear panels is preferably monolithic and arcuately formed so as to be composed of members that when assembled together extend relative to one another to form a closed four sided figure. The angularly disposed members of each preferably monolithic panel are joined together through an arcuate or looped section. The respective looped sections have generally the same cross-sectional profile so that they can be nested together in the disassembled configuration. The angular extent of the arcs through which the loop portions extend is such that proximal ends of the portions that join the loop portions extend approximately either horizontally or vertically. The separate panels can be joined together by mounting members, for example, fastening members secured at the intersections of the panels so that the respective looped sections are diagonally opposed to one another across a generally four-sided assembly. The generally monolithic front panel provides sections that serve as the seat member, front leg members, and, optionally, a chair back member. The sections of the generally monolithic rear panel form the rear leg members and a brace member extending between the normally lower ends of the front and rear leg members. The brace member is positioned close to the floor and approximately parallel to the seat member in the assembled configuration. The leg members extend approximately normal to the seat member. Mounting members are provided at the lower front and upper rear corners of the chair.

In a preferred embodiment the looped sections of both the front and rear panel members are formed on the same or a substantially identical mold. Preferably, the same mold also serves to form the back portion of the front panel and the arcuate section through which the seat portion is joined to the back portion. When the chair back is formed separately of the front panel, the same mold is also used, except the sheet of material that is molded is shorter. Thus, all of the chair members are preferably made in the same mold. This substantially reduces the cost of tooling and the space required to use and store the tooling. A chair made in such a single mold can be configured in several different ways. The arms of the rear panel are preferably of slightly different lengths. This differential length provides adjustability to the chair. Placing the shorter arm in the generally upright position causes the seat member to recline somewhat as compared to a configuration where the longer arm of the rear panel is in the generally upright position. Further, in a configuration where the back member is separate, the front and rear panels are preferably identical or substantially the same. The assembly of these identical panels permits several configurations, for example, the normally generally horizontal portions can be the same or different lengths as can the normally upright portions.

The ends of the sections of a panel that are remote from the loop portions serve as locations for mounting that panel to another panel. These distal mounting ends are preferably flared through an arc. The centers of these flare arcs at the distal mounting ends of a panel are preferably located on the opposite side of the panel from the center of the arc that defines the loop section. Thus, the mounting ends preferably flare away from the loop section. The flared mounting ends of separate panels are preferably brought together so that the mating mounting ends of the adjacent panels flare away from one another. These mounting ends thus present mating surfaces to one another when separate panels are brought together. The oppositely arced loop portions of the respective panels are thus generally diagonally opposed to one another across a generally four sided closed structure that is defined by the opposed sections of the respective mating panels. The flare angles of the mounting ends at the locations of contact are preferably such that the mating surfaces of the respective panels meet along at least a contact line and preferably along a contact surface. Releasable fastening members that compressively draw the two arcuate panels together at these contact locations serve to secure the adjacent panels together.

In a preferred embodiment, the respective arcs of the arcuate portions of the panels are smooth. The looped sections of the panels are preferably symmetrical about a plane that includes the center of the arc of the looped section and passes through the looped portion at the location of the shortest radius. Other forms where the arcs are faceted, irregular, or distorted are also possible for use according to the present invention, as will be understood by those skilled in the art.

A preferred material for use in constructing chairs according to the present invention is plywood. Plywood in flat preformed sheets is readily available, easily formed with inexpensive tooling, safe to handle and dispose of, strong, rigid, aesthetically pleasing, and reasonably priced. Flat plywood sheets are readily available in different grades and with different dimensions to provide the desired strength and rigidity. Typically, flat plywood sheets can not be formed into compound curves without splitting. The objectives of the present invention are fully realized without the use of compound curves, thus making it possible to enjoy all of the advantages of using plywood. Other materials that are capable of being formed into compound curves can be used if desired, as will be understood by those skilled in the art. Typically, compound curves are formed using materials that are either flowable, such as molding resins, or are fragmented resin impregnated solids that are laid up in the desired shape before being cured into a solid integral form.

The members of the chair in a preferred embodiment are joined with a minimum number of fasteners, preferably four. The use of two spaced apart releasable fastener members at each pair of adjacent mounting ends provides a safe, sturdy, rigid chair structure. Preferably, the fastening members include a threaded fastener element and a threaded nut element for each joint. The fastener, for example, can be a screw, and the insert can be a specially shaped nut for the screw. The joints can be achieved, for example, by mounting the nut element in a pocket in one mounting end so that the screw must pass through both adjacent mounting ends to make threaded engagement with the nut element. Tightening the screw in the nut draws the two mounting ends together. When the fastener is fully tightened with the insert in the pocket, the respective panels are compressively pre-loaded against one another. This nut and screw fastening member is preferred, as it is low in cost and exhibits high strength characteristics that are repeatably achieved over numerous cycles of assembly and disassembly. This fastening member is also particularly useful when the chair is constructed, for example, from shaped plywood sheet members, although other fastening systems could be used, if desired, as will be understood by those skilled in the art.

The front panel member in one preferred embodiment can include a back support portion that projects at a comfortable angle upwardly from the region of the seat portion. The seat portion generally projects approximately horizontally. The upwardly extending portions of the respective panel members that serve as leg members generally project generally vertically between the seat panel and the supporting substrate upon which the chair rests. The leg members engage the supporting structure through load bearing regions.

The panel members are preferably fabricated, for example, from initially flat generally two-dimensional sheets such as, for instance, plywood, plastic, laminated fiberboard, or the like, that are shaped to the desired arcuate form by molding or other shaping process.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention provides its benefits across a broad spectrum of dismantleable furniture. While the description which follows hereinafter is meant to be representative of a number of such applications, it is not exhaustive. As those skilled in the art will recognize, the basic methods and apparatus taught herein can be readily adapted to many uses. It is applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.

Referring particularly to the drawings for the purposes of illustration and not limitation:

FIG. 1 is an exploded isometric view from the left front of a preferred two panel embodiment of the invention.

FIG. 2 is an isometric view of the embodiment shown in FIG. 1 with the generally monolithic panels disassembled from one another and stacked in nested relationship for storage.

FIG. 3 is an isometric view in the assembled configuration from the right front of the embodiment shown in FIG. 1.

FIG. 4 is an isometric view in the assembled configuration of the embodiment shown in FIG. 1 from the left rear.

FIG. 5 is an isometric view in the assembled configuration of the embodiment shown in FIG. 1 from the left rear in the upright configuration placed side by side with FIG. 6 for the purpose of comparison of upright and reclined configurations.

FIG. 6 is an isometric view in the assembled configuration of an alternative configuration of the embodiment of FIG. 1 shown from the right rear side in the reclined seating position for comparison with the upright position shown in FIG. 5.

FIG. 7 is a side elevational view of the normally left side of a back free panel positioned in an upright configuration corresponding to FIG. 5, and positioned next to FIG. 8 for comparison purposes.

FIG. 8 is a side elevational view of the normally right side of a back free panel positioned in a reclined configuration corresponding to FIG. 6, and positioned next to FIG. 8 for comparison purposes.

FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 3.

FIG. 10 is a cross-sectional view taken along line 10-10 in FIG. 3.

FIG. 11 is an exploded isometric view from the left front of a preferred three panel embodiment wherein the normally front and rear panels are substantially the same.

FIG. 12 is an assembled isometric left front view of the embodiment of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout the several views, there is illustrated generally at 10 a dismantleable chair of the present invention. The dismantleable chair 10 comprises a generally monolithic front panel member 12, which serves as a normally front support member, and a generally monolithic rear panel member 14, which serves as a normally rear support member. Front and rear mounting members are provided, in the form, for example, of fastening members composed, for example, of sleeve nuts 24 and mating joint connector bolts 26 are mounted to panel members 12 and 14 through, for example, mounting holes 28. Other suitable releasable connector members and mounting arrangements can be used as will be understood by those skilled in the art. As shown, for example, in FIG. 1, a loop portion 13 is disposed intermediate the end edges 16 and 18 of panel member 12. Likewise, a loop portion 15 is illustrated disposed intermediate the end edges 20 and 22 of Panel member 14. The generally upright portion of panel member 12 between loop member 13 and lower edge 16 serves as the front legs of chair 10. Mounting holes 28 adjacent lower edge 16 extend through the distal end of the leg portion. The proximal end of the generally upright portion of panel member 12 merges into loop portion 13. Likewise, the proximal end of the seat portion of panel member 12 merges into loop portion 13. The distal end of the seat portion includes another set of mounting holes 28. Panel member 12 differs from panel member 14 in that a generally upright back portion extents normally upwardly from the region of the mounting holes 28 in the distal end of the seat portion and terminates in normally upper edge 18.

As shown, for example, in FIG. 2, when the four fastening members are removed the two panel members 12 and 14 can be nested together for transportation and storage. The arcuate cross-sectional profiles of the respective loop portions or sections are substantially the same, so they fit together as shown in FIG. 2.

With particular reference to FIGS. 3, 9, and 10, the concave surface 40 is provided to enhance the comfort for the user of the chair. Surface 42 is located at the transition between the rearward mounting end of the seat portion of Panel member 12 and the back member. There are no compound surfaces in chair 10. The concave surface 40 has transitioned smoothly to a flat surface at 42 before moving into the radiused portion that forms the flair angle that is present at the rearward mounting end of the seat section of panel member 12.

Attention is invited to FIGS. 5, 6, 7, and 8 wherein the inclined and upright configurations of the chair are illustrated. The two arm portions of Panel member 14 are of different lengths, with the longer arm portion terminating at edge 22. See particularly FIGS. 7 and 8. In the upright configuration shown in FIG. 5 (chair 30) the longer arm portion of panel member 14 is positioned in the upright position so that the rear of the seat portion of panel member 12 is elevated somewhat. In FIG. 6 chair 32 is reclined with the back not as upright as chair 30 in FIG. 5. The differences in the back angle between the upright and reclined configuration can range from approximately 10 to 40 or more degrees. In a typical chair, the longer arm section of panel member 14 when positioned upright would be about 18 inches from edge 22 to floor 38, and the shorter arm when positioned upright would be about 17 inches from edge 20 to floor 38. In, for example, children's furniture or in chairs designed for extremely tall people, these lengths would be different, as will be understood by those skilled in the art. Either arm portion can be used as the generally upright front or rear support member.

As shown particularly in FIG. 8, the respective mounting ends of the panel members are flaired away from the arc of the looped portion for mounting purposes. The center of the radius of the looped portion is on the opposite side of the panel member from those of the flaired mounting ends. The distal mounting end adjacent edge 20 is flaired through an arc to provide a flair angle 19. Likewise, the other distal mounting end adjacent edge 22 is flaired to provide a flair angle 17. Flair angles 17 and 19 are approximately the same. The mating distal mounting ends of Panel member 12 are likewise flaired at approximately the same flair angles so as to provide mating mounting locations. Positioning the panel members adjacent one another with the respective flair angles congruent permits the holes 28 to be brought into registry so that the nuts 24 and screws 26 can be threadably engaged.

Preferably, the flair angles and the lengths of the respective mounting ends are such that the lower front edge of the rear panel member bears solidly on the upper surface of floor 38 or other supporting substrate. This serves to stabilize the chair. The loop portion of the rear panel member pears against solidly against the substrate 38. Preferably, the lower front edge and loop portion of the rear panel member bear against the supporting substrate at least at the opposite sides of the panel so the contact is separated by the full width of the panel. Typically, both the lower front edge and the loop portion contact the supporting substrate along a line of contact that extends substantially across the width of the panel.

With particular reference to FIGS. 11 and 12, a three panel embodiment 34 is illustrated. Back panel member 36 is separate from the front panel member. This provides a shorter package when the chair 34 is disassembled. The flair angles of the respective mating mounting ends are generally approximately the same so that only two fastening members serve to secure the flaired proximal end adjacent edge 44 of back panel 36 to the other two panel members. The panel members 14 that serve as both the front and rear panel members of chair 34 are substantially the same. As illustrated, the end edges 22 of the longer arm portions of panels 14 are joined at the upper rear of the generally four sided figure that is formed by assembling panel members 14 and 36 together. Other configurations are possible. For example, both end edges 22 could be used to form the lower end of the front upright of the chair 34, or one of the respective end edges 22 could be placed at the upper rear and the other at the lower front of chair 34. Different chair backs with different back angles, heights, patterns, forms, and the like, can be used, if desired. Different chair backs can be provided with one set of front and rear panel members so that different functionality or aesthetic effects can be achieved by swapping chair backs.

In the embodiments chosen for purposes of illustration the intially flat sheets from which the respective panel members are formed are left in their original thicknesses. Where the panel members have some appreciable thickness they can be sculpted somewhat by removing some of the material of the sheets. This allows, for example, modest compound curves to be formed in material such as plywood where it is not possible to form compound molded curved surfaces.

What have been described are preferred embodiments in which modifications and changes may be made without departing from the spirit and scope of the accompanying claims. 

1. A dismantleable chair comprising: a front panel formed from a generally monolithic sheet of material and including a leg portion having proximal and distal ends, a seat portion having proximal and distal ends, and a first loop portion intermediate said leg and seat portions, said distal ends being remote from said first loop portion, said first loop portion having a first arcuate cross-sectional profile, said leg and seat portions extending angularly of one another; a rear panel formed from a generally monolithic sheet of material and including a first arm portion having a proximal end and a distal end, a second arm portion having a proximal end and a distal end, and a second loop portion intermediate said arm portions, said distal ends being remote from said second loop portion, said second loop portion having a second arcuate cross-sectional profile, said first and second arcuate cross-sectional profiles being generally the same, whereby said first and second loop portions being adapted to being nestled together when said disassemblable chair is in a disassembled configuration; and at least one first fastening member adapted to releasably fastening said distal end of said leg portion to a distal end of one of said first or second arm portions, and at least one second fastening member adapted to releasably fastening said distal end of said seat portion to the distal end of the other of said first or second arm portions.
 2. A dismantleable chair of claim 1 wherein said first and second arm portions are of different lengths.
 3. A dismantleable chair of claim 1 wherein said front panel includes a back portion integral with and projecting normally upwardly from said distal end of said seat portion.
 4. A dismantleable chair of claim 1 including a back panel having proximal and distal ends, said proximal end of said back panel being adapted to being secured to said distal end of said seat portion.
 5. A dismantleable chair of claim 1 wherein said front and rear panels generally have no molded compound curves.
 6. A dismantleable chair of claim 1 wherein said first and second loop portions are adapted to being positioned generally diagonally opposed to one another across a rectangle when said dismantelable chair is in an assembled configuration.
 7. A dismantleable chair of claim 1 wherein said seat and leg portions extend approximately normal to one another when said dismantelable chair is in an assembled configuration.
 8. A dismantleable chair of claim 1 wherein said first and second arm portions extend approximately normal to one another when said dismantelable chair is in an assembled configuration.
 9. A dismantleable chair comprising: a front support member, said front support member being an arcuately formed generally monolithic sheet of material having a rearward mounting end, a lower mounting end, and a first curved section disposed intermediate said rearward and lower mounting ends, said first curved section extending through a first arc, said rearward mounting end being spaced from said curved section and flared away from said first arc at a rearward flare angle, said lower mounting end being spaced from said first curved section and flared away from said first arc at a lower flare angle; a rear support member, said rear support member being an arcuately formed generally monolithic sheet of material having a first mounting end, a second mounting end, and a second curved section disposed intermediate said first and second mounting ends, said second curved section extending through a second arc, said first and second mounting ends being spaced from said second curved section and flared away from said second arc at first and second flare angles, respectively, said first and second curved sections having generally the same cross-sectional profile whereby said front and rear support members are adapted to being nested together when said disassemblable chair is in a disassembled configuration; and at least one front mounting member adapted to secure said lower mounting end to one of said first or second mounting ends, and at least one rear mounting member adapted to secure said rearward mounting end to the other of said first and second mounting ends.
 10. A dismantleable chair of claim 9 wherein said front and rear support members generally have no molded compound curved surfaces.
 11. A dismantleable chair of claim 9 wherein said flare angle of said lower mounting end is approximately the same as said flair angle of said first mounting end when said first mounting end is secured to said lower mounting end, and said flare angle of said rearward mounting end is approximately the same as said flair angle of said second mounting end when said rearward mounting end is secured to said second mounting end.
 12. A dismantleable chair of claim 9 wherein said first mounting end is adapted to being secured to said lower mounting end when said disassemblable chair is in an assembled configuration.
 13. A dismantleable chair of claim 9 wherein said first mounting end is adapted to being secured to said rearward mounting end when said disassemblable chair is in an assembled configuration.
 14. A dismantleable chair of claim 9 wherein said first and second arcs are of such an angular extent that said front and rear support members form a generally four sided figure with said first and second curved sections generally diagonally opposed to one another when said disassemblable chair is in an assembled configuration. 